Apparatus for making wheel covers



Dec. 15, 1953 G. A. LYON 2,662,499

APPARATUS FOR MAKING WHEEL COVERS Filed June 21, 1949 3 Sheets-Sheet l m0 C L E N W G m AM on 0 P. S U T A R A D: P A

Dec. 15, 1953 3 Sheets-Sheet 3 Filed June 21, 1949 al 271 5.27 far660%66 55m" [ya/v Patented Dec. 15, 1953 UNITED STATES ATENT OFFICE2,662,499 APPARATUS FOR MAKING WHEEL COVERS George Albert Lyon, Detroit,Mich. Application J une 21, 1949, Serial No. 100,368

1 Claim.

The present invention relates to improvements in an apparatus for makingwheel covers and more particularly wheel covers of the kind that areadapted for use to protectively and ornamentally cover the outer side ofautomobile wheels.

An important object of the present invention is to provide an improvedapparatus for making vehicle wheel covers.

A further object of the invention is to provide an improved apparatusfor simply and emciently forming a bulged configuration in the marginalportion of a full disk wheel cover.

According to the general features of the present invention there isprovided an apparatus for making vehicle wheel covers, a rigidsupporting block, a resiliently pliable annulus of rubbertype materialcarried by said block and providing the sole support for a wheel coverblank having a generally channel-shaped formation with which thesupporting surfaces of the annulus are substantially complementary, andforming die means having complementary formation to the upper surface ofthe cover member and a cover margin receiving groove formation adjacentto and opening toward a marginal portion of the cover and the peripheryof the supporting annulus, said die means being operable to press thecover against the supporting annulus to deflect the supporting annulustoward said forming groove to drive the cover marginal portion bulginglyinto said forming groove.

According to other general features of the invention the supportingblock and the die means include generally convergently related surfacesgenerally converging toward the forming groove in order to facilitatedeflection of the material of the annulus into the forming groove.

According to still other general features of the invention means areprovided for restraining deflection of the supporting annulus to anysubstantial extent away from the forming groove, but aflording a smallclearance with respect to the die means in the fully compressedcondition of the die means whereby to afford a small pressure reliefclearance for the inner margin of the annulus.

Other objects, features and advantages of the present invention will bereadily apparent from the following detailed description of a preferredembodiment thereof taken in conjunction with the accompanying drawingsin which:

Figure 1 is a diametrical sectional view through a full disk cover blankadapted to be further processed according to the present invention;

Figure 2 is a top plan view of the blank;

Figure 3 is a fragmentary enlarged radial sectional view through theblank showing the same after a further step in the formation thereof;

Figure 4 is a fragmentary vertical sectional detail view through theapparatus for further shaping the cover blank and showing the blankaccording to Figure 3 in the apparatus ready for further processing;

Figure 5 is a sectional detail view similar to Figure 4, but showing theapparatus in the relative functional relationship assumed uponcompletion of the marginal bulging of the cover blank;

Figure 6 is a radial marginal sectional view through the cover blank asit appears following the operation of Figure 5 and disclosing the finalformation of a portion of the blank to complete the wheel cover;

Figure '7 is a side elevational view of a vehicle Wheel assembly showingthe completed cover in position on the wheel; and

Figure 8 is an enlarged radial sectional view taken substantially online VIIIVIII of Figure 7.

As shown on the drawings:

In the manufacture of the type of full disk wheel cover which isconstructed to cover substantially the entire outer side of a vehicleWheel such as an automobile wheel and engage in selfretaining relationwith the tire rim, an especial problem has existed in the formation ofthe marginal portions of the cover and it is to the solution of thisproblem that the present invention is particularly directed. To thisend, a cover blank I0 is first drawn, or stamped from a sheet metalblank to the form. shown in Figures 1 and 2. This comprises a crownportion H and an annular portion 12 surrounding the crown portion andjoined therewith in one piece by an inwardly directed annular ribjuncture I 3. In the present instance the annular portion is ofgenerally convex concave, or curved cross-section. The margin of theblank is provided with an angular flange formation including a generallycylindrical flange vals, herein shown as six in number with truncatedcorner portions I7. Thereafter, the flange extremity portion I5 is bentinto substantially cylindrical rearwardly extending concentricity withthe flange portion M, as shown in Figure 3.

In the completed cover it is desirable to have a marginal portion thatwill extend radially outwardly beyond and in concealing relation to theher or synthetic rubber, or

inturned marginal flange portion. For this purpo e the gen rallycylindrical flange portion 14, which is adjacent to the annular coverportion 52, is bulged uniformly radially outwardly substantially beyondthe cylindrical diameter of the inner flange portion l5 and the flangeextremities ll.

According to the present invention bulging of the flange portion id iseffected by pressing a resiliently deflectable forming member which ispreferably in the form of a rubber-like annulus uniformly radiallyoutwardly into the reentrant corner defined between the annular coverportion l2 and the flange Hi, while holding the flange portion iii toits original diameter. In accomplishing this result, the rubberkeannulus is squeezed while confined against substantial move ment in anydirection except radially outwardly against the flange portion l4, butwith limited pressure relief movement of the annulus radially inwardlyso as to avoid blocking and at least overheating from excessivepressure. The pressure on the annulus is applied between opposedsurfaces converging generally toward the point of application of usefulpressure at the inner side of the flange portion i l of the cover blankadjacent the iuncture thereof with the annular cover portion l2. v Thenovel apparatus for carrying out the foregoing method is shown inFigures and 5 and comprises relatively reciprocable opposed members l8and i9, either or both of which may be reciprocably movable relative tothe other. In the present in tance the member l8 comprises a die blockor anvil which is stationary and may be mounted on a press bed. On theupper margin of the lower stationary member I8 is provided a pressureridge 2@ having an outer diameter substantially equal to the innerdiameter of the flange !5 of the cover blank so as to fit within thecover flange substantially as shown in Figure e. At its inner side, thepressure ridge 2B is formed with a diagonal pressure face 2| merging atits lower end with the upper face of the pressure block I8. v

Mounted on the pressure face 2! is a forming annulus 22 which ispreferably formed from rubequivalent material having the characteristicof resilient deflectability, but non-compressibility. That water itsubstantially resists compression, but will tend to escape bysubstantial flowing action from the pressure applied thereto. A lowerradially inwardly extending attachment flange 23 on the resilientlyyieldable annulus is engaged by hold down flange annulus 2A which may besecured removably to the inner upper surface of the pressure block is bymeans of bolts 25. Actual hold down, or clamping of the attachmentflange 23 is effected by a flange portion 21 which where it opposes thebody of the resilient annulus 22 is of rounded, configuration, beingpreferably of substantially bulbous cross-section.

The structure and the relationship of the resiliently yieldable annulus22 is such that it fits within the reentrant marginal corner portion ofthe cover blank it and against the inner face of the cover annularportion l2 and in assembly of the cover blank with the resilient annuluspreparatory to the forming operation serves as the sole support for thecover blank in the apparatus. For this purpose the outer periphery ofthe resilient annulus is preferably formed cylindrically concentric withthe periphery of the pressure ridge 2%! and extends to a substantial is,like height above the peak of the pressure ridge. The upper surface ofthe resilient annulus is preferably formed substantially complementaryto the inner surface of the annular cover portion 12. Hence, in theassembled condition, the resilient annulus fits fairly closely withinthe engaged portion of the cover blank.

The upper pressure member is is preferably contoured complementary tothe configuration of the cover blank Hi and thus engages the crownportion ll and the annular portion 52 as well as the juncture rib it ofthe cover blank snugly when placed in engagement with the cover blank.Thereby these portions of the cover blank are held against deformationincident to further forming of the cover blank in the apparatus.

In order to accommodate bulging of the flange portion l4 of the coverblank and to form the bulged portion to preferred contour radius, thepressure member, or block is is formed with a bulge forming groove 23immediately adjacent to the marginal external corner of the cover blank.By preference, however, the groove 28 is only partial with respect tothe completed bulge desired and a companion groove 29 is provided in arigid forming ring 3B which surrounds the pressure ridge 2t and projectstherea-bove sufliciently to provide for the forming groove 29. In orderto accommodate the flange portion l5 of the cover blank between theupper part of the pressure ridge 2% and the adjacent portion of theforming ring til, a space 31 is provided therebetween in which theflange l5 extends during the forming operation and within which theflange i5 is held to its original cylindrical diameter whilenevertheless permitting the flange to move freely axially.

In operation, relative axial movement of the pressure block members ISand I9 is effected, as for example, by driving the member 19 toward themember 18 to thereby place the resilient f orrning annulus 22 undercompression between the pressure ridge 2% and the opposing surface ofthe annular cover portion :2 as backed up by the complementary surfaceof the pressure block iii. By reason of the cover contour, and moreespecially the contour of the annular cover portion {2 which faces onits inner surface generally axially inwardly and radially outwardly andis disposed generally convergent at the radially outer side with respectto the pressure surface 2| of the pressure ridge, the resilient formingannulus 22 is resiliently deflected toward the cover blank flange I4 asthe pressure is applied to the forming annulus. As a result, the coverflange I4 is bulged outwardly by the force of the deflected outermarginal portion of the forming annulus. Bulging deflection of the coverblank continues until the blank has been shaped firmly and uniformlyinto the forming grooves 28 and 23 to assume the desired contour of thebulge substantially as shown in Figure 5.

During the pressing operation, the securing flange 21 provides an innermarginal backing for the forming annulus 22 and resists substantialdeflection radially inwardly of the annulus under the pressure so thatmaximum forming pressure is exerted radially outwardly by the formingannulus to effect the bulging deformation of the cover margin. Since theretaining flange 2'! is of rounded contour the resilient forming annulusis safe from any cutting damage by exertion of pressure against theretaining flange.

For pressure relief a limited inner peripheral portion of the resilientforming annulus 22 is permitted to deflect radially inwardly between thetop of the retaining flange 2'5 and the rib l3 of the cover blankaffording a predetermined pressure relief gap, Through this arrangement,extreme accuracy in the volume of the resilient forming ring 22! isunnecessary because pressure relief from blocking pressure is affordedin the gap between the rib is and the flange 2?. Furthermore,over-heating due to o-vercompression of the resilient forming annulus isthereby avoided Among the advantages of using a resilient formingannulus for forming the peripheral bulge in the cover resides, ofcourse, the fact that upon releasing the forming pressure upon theannulus it immediately resiliently resumes its original shape and thusautomatically withdraws from the bulge so that the now additionallyformed cover blank can be lifted away from the annulus. This method offorming the bulge also has the salient advantage of low cost from thestandpoint of die manufacture since substantial dimensional tolerance inthe form of the resilient annulus is permitted because it conforms tothe shape of the rigid metal dies during the pressing operation and thusneed not be Very accurately shaped to begin with, but only need beshaped to approximate complementary form of the inside shape or thecover blank portions l2 and it. The original dimensions of the resilientannulus are preferably at least slightly undersize rather than oversizein order to facilitate placement and removal of the cover blank. Wear isa negligible factor with respect to the resilient annulus itself, andwear upon the cooperating metallic die members is also reduced becauseof the facility of the resilient annulus to conform itself to anyimperfections in the forming surfaces of the rigid die members. Thesimplicity of the one piece resilient annulus as a forming die elementis also an important die cost factor.

After the cover blank it has been formed with the peripheral bulge andis removed from the resilient forming annulus, the corner portions llare turned generally radially and axially outwardly from the dashoutline position to the full line position as shown in Figure 6 toprovide cover retaining fingers and the cover is ready for applicationto a vehicle wheel. Any appropriate finish may be afforded for theouter, exposed side of the cover such as a natural polish, or plating,or any appropriate color finish, or any combination of finishespreferred.

As shown in Figures 7 and 8, a wheel to which the finished cover ii! maybe applied comprises a load-sustaining body portion 35 and a tire rim35, the latter being of the multi-flanged drop-center type including abase flange 31 to which the loadsustaining body portion 35 is attached,an outer side flange 38, an intermediate flange 3d and a terminal flangestructure so. The outside diameter of the cover terminal flange l isslightly less than the inside diameter of the intermediate flange of thetire rim, while the outside diameter of the peripheral bulge provided bythe bulged flange i l is substantially greater than the inside diameterof the terminal flange in the tire rim. The outside diameter of a circledescribed by the turned out terminal corners l! is somewhat greater thanthe inside diameter of the intermediate flange 39. As a result, when thecover is centered with respect to the outer side of the wheel, theterminal corner portions ll engage against the shoulder providing ajuncture between the intermediate flange 39 and the terminal flange 4dand as the cover is pressed axially inwardly, the terminal portions llride inwardly along the surface of the intermediate flange 39 and flexthe flange I 5 radially inwardly whereby a strong radially outwardlygripping action of the terminals l 7 against the intermediate flange 39eifects a wedging biting engagement which is effective to retain thecover on the wheel in service. Since the peripheral bulge it overliesthe juncture shoulder between the adjacent flanges of the tire rim, iteffectively conceals the gap between the flange l5 and the intermediateflange 39 of the tire rim. In addition, the peripheral bulge affords astrong marginal reinforcement for the cover and rendering the radiallyprotruding portion of the margin substantially rigid and enhancing theresilient flexibility of the marginal retaining flange l 5. The bulgealso affords a convenient pry-off rib between which the adjacentshoulder on the tire rim the pry-off tool can be conveniently interposedto pry the cover free from the Wheel when required, the resilience ofthe retaining flange it making such pry-off feasible.

I claim as my invention:

In apparatus for making wheel covers, a circular stationary memberfacing upwardly and having a peripheral upwardly projecting annularridge provided with a cylindrical radially outwardly facing face and aradially and axially inwardly sloping inner face merging with anupwardly facing surface of said member at the base of said sloping innerface, a resilient annulus having the characteristics of rubber having asurface complementary to and lying against said inner face, said annulushaving a body portion of substantial, thickness projecting upwardlyabove the peak of said ridge and tapering radially inwardly and thendropping axially downwardly to a radially inwardly extending flangesubstantially thinner than the height of said body, an annular hold-downflange member secured to said upwardly facing member radially inwardlyof said annulus flange and having a radially outwardly extending flangeportion upwardly offset relative to said upwardly facing member andclampingly engaging said annulus flange, said flange portion being ofbulbous cross-section opposing the radially inner side of said annulusbody and with the annulus body rising to a substantial heightthereabove, a pressure member reciprocably overlying said upwardlyfacing member having an annular portion opposing the body of saidannulus and with the surface of said annular portion sloping inwardlyand merging with an annular downwardly projecting rib opposing saidbulbous holddown flange portion so that when said pressure member isthrust downwardly against said annulus said annulus body is squeezed toflow radially outwardly beyond the peak of said ridge while a radiallyinner portion of the annulus body flows radially inwardly over saidbulbous holddown flange portion and under said pressure member rib, saidpressure member having a portion thereof extending radially outwardlybeyond said annulus and defining a downwardly opening annular forminggroove of limited radially outwardly extent, and a holding memberadapted to clamp against said cylindrical surface of said ridge, acylindrical flange on a cover member 'esting upon said annulus, saidholding member to said groove in the ing a portion of said into bydisplacement cident to pressure applied thereagainst by said Numberpressure member. 2,330,228 GEORGE ALBERT LYON. 2,458,854 2,467,930References Cited in the file of th1s patent 5 UNITED STATES PATENTSNumber Number Name Date 5 430 1,921,188 Ireland Aug. 8, 1933 2,304,581Lyon Dec. 8, 1942 2,313,689 Waters Mar. 9, 1943 Name Date Lyon Sept. 28,1943 Hull et a1 J an. 11, 1949 Coyle Apr. 19, 1949 FOREIGN PATENTSCountry Date Sweden Sept. 1, 1894

